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CHARACTERISATION OF SOFT MAGNETIC COMPOSITES

Neethirajan, Rajesh Krishnan LU (2025) MMTM05 20251
Production and Materials Engineering
Abstract
Soft Magnetic Composites (SMCs) represent a new generation of materials gaining attention for their effective use in electric motors and transformers. The strong magnetic properties, reduced eddy current losses, and flexibility in forming complex 3D shapes. They offer clear advantages over traditional laminated steels, especially in the designs where magnetic behavior is needed in all directions. SMCs are made from iron particles coated with an insulating layer, offer a unique combination of design flexibility and functional efficiency, making them well-suited for complex electromagnetic applications. This study focuses on exploring the microstructure and porosity of SMCs, aiming to better understand and improve their role in... (More)
Soft Magnetic Composites (SMCs) represent a new generation of materials gaining attention for their effective use in electric motors and transformers. The strong magnetic properties, reduced eddy current losses, and flexibility in forming complex 3D shapes. They offer clear advantages over traditional laminated steels, especially in the designs where magnetic behavior is needed in all directions. SMCs are made from iron particles coated with an insulating layer, offer a unique combination of design flexibility and functional efficiency, making them well-suited for complex electromagnetic applications. This study focuses on exploring the microstructure and porosity of SMCs, aiming to better understand and improve their role in electromagnetic systems, particularly in motor component applications. The analysis of SMC materials fabricated through conventional die compaction methods, using high-purity iron powder coated with insulating layers. Samples were subjected to systematic surface preparation and examined using digital optical microscopy combined with image processing techniques in ImageJ. Quantitative parameters such as particle size, coating area, and pore equivalent diameter were extracted from nine distinct regions across the samples. The results reveal significant Variation across regions. This non-uniformity affects the electromagnetic properties of SMCs but also suggests unequal pressure distribution during compaction. These findings provide valuable insight into optimizing compaction parameters and improving the homogeneity and functional performance of soft magnetic materials. (Less)
Popular Abstract
What makes electric cars and modern appliances run more efficiently? One answer is in the materials inside their motors specifically, Soft Magnetic Composites (SMCs).These materials made by pressing tiny iron particles coated with insulation into solid shapes. Unlike traditional metal sheets used in motors, these composites allow for electricity to flow more smoothly and designs to be more compact and efficient.
In this study, we looked at how these materials are built on a microscopic level and how that affects their performance. Using advanced microscopes and image software, we examined samples of SMCs used to make motor parts. We studied three things such as
• The size and shape of the iron particles,
• The evenness of their... (More)
What makes electric cars and modern appliances run more efficiently? One answer is in the materials inside their motors specifically, Soft Magnetic Composites (SMCs).These materials made by pressing tiny iron particles coated with insulation into solid shapes. Unlike traditional metal sheets used in motors, these composites allow for electricity to flow more smoothly and designs to be more compact and efficient.
In this study, we looked at how these materials are built on a microscopic level and how that affects their performance. Using advanced microscopes and image software, we examined samples of SMCs used to make motor parts. We studied three things such as
• The size and shape of the iron particles,
• The evenness of their insulation coating
• The distribution of pores.
We discovered that the way these particles are pressed together can create uneven structures. The different regions of the samples top, middle, and bottom shows variations in pore size and coating thickness and pore size which can affect performance by creating uneven magnetic properties and increasing energy losses. However, using a cube shape and a better pressing method resulted in a much more even structure ideal for making strong energy efficient motor parts.
This research helps manufacturers understand how to make better motors for electric vehicles and electronics by improving the production of these magnetic composites. Better structure means less energy wasted and more reliable devices benefiting both industries and the environment. (Less)
Please use this url to cite or link to this publication:
author
Neethirajan, Rajesh Krishnan LU
supervisor
organization
course
MMTM05 20251
year
type
H2 - Master's Degree (Two Years)
subject
keywords
SOFT MAGNETIC COMPOSITES
language
English
id
9198448
date added to LUP
2025-06-16 15:04:47
date last changed
2025-06-16 15:04:47
@misc{9198448,
  abstract     = {{Soft Magnetic Composites (SMCs) represent a new generation of materials gaining attention for their effective use in electric motors and transformers. The strong magnetic properties, reduced eddy current losses, and flexibility in forming complex 3D shapes. They offer clear advantages over traditional laminated steels, especially in the designs where magnetic behavior is needed in all directions. SMCs are made from iron particles coated with an insulating layer, offer a unique combination of design flexibility and functional efficiency, making them well-suited for complex electromagnetic applications. This study focuses on exploring the microstructure and porosity of SMCs, aiming to better understand and improve their role in electromagnetic systems, particularly in motor component applications. The analysis of SMC materials fabricated through conventional die compaction methods, using high-purity iron powder coated with insulating layers. Samples were subjected to systematic surface preparation and examined using digital optical microscopy combined with image processing techniques in ImageJ. Quantitative parameters such as particle size, coating area, and pore equivalent diameter were extracted from nine distinct regions across the samples. The results reveal significant Variation across regions. This non-uniformity affects the electromagnetic properties of SMCs but also suggests unequal pressure distribution during compaction. These findings provide valuable insight into optimizing compaction parameters and improving the homogeneity and functional performance of soft magnetic materials.}},
  author       = {{Neethirajan, Rajesh Krishnan}},
  language     = {{eng}},
  note         = {{Student Paper}},
  title        = {{CHARACTERISATION OF SOFT MAGNETIC COMPOSITES}},
  year         = {{2025}},
}